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CGi Gas Boiler Series 4

Weil-McLain CGi Gas Boiler Series 4 User manual

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Part Number 550-142-301/0420
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your
building.
• Immediately call your gas supplier from a neighbor’s phone. Follow
the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service
technician or the gas supplier.
If the information in this manual is not followed exactly, a fire or
explosion may result, causing property damage, personal injury or
loss of life.
CGa Series 3, CGi Series 4,
EG Series 5, PEG Series 5,
LGB Series 2
Gas-Fired Boilers
User’s
Information
Manual
INSTALLER:
Please take time to review this User’s information
Manual with the boiler owner. Explain all maintenance
and service
procedures and the correct Operating
Instructions.
2
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Please read this page first
How to use this
manual . . .
The Boiler manual is for use only by a qualified heating installer/service technician.
Refer only to this User’s Information Manual for your reference. Improper installation,
adjustment, alteration, service or maintenance can cause property damage, personal
injury (exposure to hazardous materials) or loss of life. Installation and service must be
performed by a qualified installer, service agency or the gas supplier (who must read and
follow the supplied instructions before installing, servicing, or removing this boiler. This
boiler contains materials that have been identified as carcinogenic, or possibly carcino-
genic, to humans).
Boiler service
and
maintenance
The following defined terms are used throughout this manual to bring attention to the presence of hazards
of various risk levels or to important information concerning the life of the product.
Hazard
definitions
Indicates presence of hazards that will cause severe personal injury, death or substantial
property damage.
Indicates presence of hazards that can cause severe personal injury, death or substantial
property damage.
Indicates presence of hazards that will or can cause minor personal injury or property
damage.
Indicates special instructions on installation, operation or maintenance that are important
but not related to personal injury or property damage.
To . . . Read/Use . . . Pages . .
Learn
precautions
Warnings and denitions
1, 2 and 3
Prevent air
contamination
Read list of air contaminants you must avoid. If found,
either remove products permanently or isolate boil-
er and provide outside combustion air.
3
Identify boiler
components
The illustration on page 4 or 5, will show you the location
of the main components.
4-5
Maintain
boiler
Set up a plan for maintaining the boiler using the
schedule included in this manual. Schedule an an-
nual start-up by a qualied service technician before every
heating season.
6-12
Start –or–
Shutdown
boiler
Use the Operating Instruction sheet for the gas
valve installed on your boiler. Ask your service techni-
cian if you are unsure which one.
12-18
Troubleshoot
common
problems
Use the common problems/solutions table to resolve
typical heating system/boiler problems.
19
When calling or writing about the boiler— Please have the boiler model number from
the boiler rating label and the CP number from the label located on the top of the boiler
next to the air inlet connection.
Freeze protection fluids —
• NEVER use automotive or standard glycol antifreeze. Use only freeze-protection fluids made for hydronic systems. Follow all
guidelines given by the antifreeze manufacturer. Thoroughly clean and flush any replacement boiler system that has used glycol
before installing the new boiler.
Frozen Water Damage Hazard
Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, or other
electrical system failures could result in frozen plumbing and water damage in a matter of hours. For your protection, take preventa-
tive actions such as having a security system installed that operates during power outages, senses low temperature, and initiates an
effective action. Consult with your boiler contractor or a home security agency.
3
Part Number 550-142-301/0420
User’s Information Manual
Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial
property damage.
STOP!! — Read before proceeding
Products to avoid
Spray cans containing chloro/
fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool
chemicals
Calcium chloride used for thawing
Sodium chloride used for water
softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in
clothes dryers
Chlorine-type bleaches, detergents,
and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building
products and other similar products
Excessive dust and dirt
Areas likely to have
contaminants
Dry cleaning/laundry areas and
establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and
establishments
New building construction
Remodeling areas
Garages with workshops
Buildings under construction
(where air is contaminated with
particulates)
Air contamination
•Topreventpotentialofseverepersonalinjuryordeath,checkforproductsor
areas listed in table at right before installing boiler. If any of these contaminants
are found:
•removecontaminantspermanently.
— OR —
•isolateboilerandprovideoutsidecombustionair.Seenational,provincialor
local codes for further information.
Service and maintenance
•Toavoidelectricshock,disconnect electrical supply before performing
maintenance.
•Toavoidsevereburns,allow boiler to cool before performing maintenance.
•Youmustmaintain the boiler as outlined in the manual and have the boiler
started up and serviced at least annually by a qualified service technician
to ensure boiler/system reliability.
Boiler operation
•Do not block flow of combustion or ventilation air to boiler. This boiler is
equipped with a control which will automatically shut down the boiler
should air or vent be blocked. If vent or air blockage is easily accessible and
removable, remove it. The boiler should attempt to restart within an hour.
If blockage is not obvious or cannot be removed, have the boiler and system
checked by a qualified service technician.
•Shouldoverheating occur or gas supply fail to shut off, do not turn off or
disconnect electrical supply to pump. Instead, shut off the gas supply at a
location external to the appliance.
•Have the building monitored when it is vacant for an extended period.
Safetycontrolscanshutdowntheboileratanytime.Thelossofheatcan
result in significant damage due to freezing.
Boiler water
•DO NOT use petroleum-based cleaning or sealing compounds in boiler
system. Water seal deterioration will occur, causing leakage between sections and
damage to heating system components. This can result in substantial property
damage.
•DONOTuse“homemadecures”or“boilerpatentmedicines”.Seriousdamage
to boiler, personnel and/or property may result.
•Continualfreshmakeupwaterwillreduceboilerlife.Mineralbuildupinsections
reduces heat transfer, overheats cast iron, and causes section failure. Addition of
oxygen and other gases can cause internal corrosion. Leaks in boiler or piping
must be repaired at once to prevent makeup water.
•Donotaddcoldwatertohotboiler.Thermalshockcancausesectionstocrack.
If any part of a boiler, burner or its controls has been sprayed with
or submerged under water, either partially or fully, DO NOT attempt
to operate the boiler until the boiler has been either replaced or
completely repaired, inspected, and you are sure that the boiler and
all components are in good condition and fully reliable.Otherwise,by
operating this boiler, you will cause a fire or explosion hazard, and an electrical
shock hazard, leading to serious injury, death, or substantial property damage.
Saltwater Damage — The exposure of boiler components to saltwater can have both im-
mediate and long-term effects. While the immediate effects of saltwater damage are similar to
those of freshwater (shorting out of electrical components, washing out of critical lubricants,
etc.), the salt and other contaminants left behind can lead to longer term issues after the water
is gone due to the conductive and corrosive nature of the salt residue. Therefore, Weil-McLain
equipment contaminated with saltwater or polluted water will no longer be covered under war-
ranty and should be replaced.
Electrical Damage — If any electrical component or wiring came into contact with water, or
was suspected to have come into contact with water, replace the boiler with a new Weil-McLain boiler.
4
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
1 Gas valve
2 Pilot burner (Not shown)
3 Main burner
4 Gas manifold/orices
5 Control module
7 Vent damper (CGa only)
8 Water temperature/LWCO sensor
9 Transformer
10 Spill switch (CGa only)
12 Rollout thermal fuse element
13 Draft hood (CGa only)
14 Circulator
15 Relief valve
16 Gauge (pressure/temperature)
17 Drain valve
Boiler components
CGa Series 3
5
Part Number 550-142-301/0420
User’s Information Manual
1 Gas valve
2 Pilot burner (Not shown)
3 Main burner
4 Gas manifold/orices
5 Control module
6 Inducer (CGi only)
8 Water temperature/LWCO sensor
9 Transformer
11 Air pressure switch (CGi only)
12 Rollout thermal fuse element
14 Circulator
15 Relief valve
16 Gauge (pressure/temperature)
17 Drain valve
Boiler components
CGi Series 4
6
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orices
5 Control module
7 Vent damper
9 Transformer
10 Spill switch
12 Rollout thermal fuse element
13 Low water cutoff (steam boilers)
14 Limit control(s)
15 Draft hood
16 Circulator
18 Gauge (pressure or pressure/temperature)
19 Gauge glass (steam only)
20 Water temperature/LWCO sensor
(For EG/PEG water boilers - not shown)
Boiler components
EG/PEG
LGB
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orices
5 Control module
7 Vent damper
9 Transformer
10 Spill switch
12 Rollout thermal fuse element
13 Low water cutoff (steam boilers)
14 Limit control(s)
15 Draft hood
16 Circulator
18 Gauge (pressure or pressure/temperature)
19 Gauge glass (steam only)
7
Part Number 550-142-301/0420
User’s Information Manual
Service technician
(covered in Boiler Manual – for use only by
a qualified service technician)
Owner maintenance
(see following pages for instructions)
AnnuAl stArt-up
Inspect:
•Reported problems
•Boiler area
•Air openings
•Flue gas vent system
•Pilot and main burner flames
•Water piping
•Boiler heating surfaces
•Burners, base and inlet air box
•Condensate drain system
Service:
•Oiled-bearing circulators
•Temperature/LWCO sensor
Start-up:
•Perform start-up per manual
Check/test:
•Gas piping
•Cold fill and operating pressures
•Air vents and air elimination
•Limit controls and cutoffs
•Expansion tank
•Boiler relief valve
Review:
•Review with owner
Daily
•Check boiler area
•Check air openings
•Check boiler pressure/
temperature gauge
Monthly
•Check boiler interior piping
•Check venting system
•Check air vents
•Check boiler relief valve
•Check automatic air vents
(if used)
Periodically
•Test low water cutoff
Every 6 months
•Operate relief valve
End of season
•Shut down procedure
Tankless water heater (EG and PEG only)
If boiler is used to supply domestic hot water, limit
control should be set to supply adequate hot water.
Weil-McLain tankless heaters are rated at 200 °F boiler
water temperature. To get rated output, set low limit at
200 °F. Limit can be adjusted to meet system hot water
requirements.Differentialcanbesetto15°andadjusted
to control level. Lowering the differential will cause a
slight variation in water temperature but will decrease
burner on-off cycling. High limit should be set at least
20 ° above low limit.
Maintain boiler using schedule below
8
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
User maintenance procedures
Donotattempttoplaceboilerinoperationifspillswitch
cuts off gas flow. Immediately call a service technician.
Failure to do so can cause severe personal injury, death
or substantial property damage.
Rollout thermal fuse element
CGa, CGi, EG, & PEG only
Cutsoff gas flowshouldflamerollout occur.See
Figure 1.
Donotattempttoplaceboilerinoperationifrollout
thermal fuse element cuts off gas flow. Immediately call
a service technician. Failure to do so can cause severe
personal injury, death or substantial property damage.
Spill switch
CGa, EG, & PEG only
Cuts off gas flow should vent system become blocked.
SeeFigure 2.
Figure 1
Rollout thermal fuse element
Figure 2
Spill switch
Component information
Boiler area
To prevent potential of severe personal injury, death
or substantial property damage, eliminate all materials
discussed below from the boiler vicinity. If found:
• Removeproductsimmediatelyfromthearea. If
they have been there for an extended period, call a
qualified service technician to inspect the boiler and
vent system for possible damage from acid corrosion.
• Ifproductscannot be removed,immediatelycall
a qualified service technician to install an outside
combustion air source for the boiler (if not already
installed).
1. Combustible/flammablematerials—Donot
store combustible materials, gasoline or any
other flammable vapors or liquids near the boiler.
Remove immediately if found.
2. Aircontaminants—Seelistingofcontaminantson
page 3.
❏ Check daily . . . . . . . . . . . . . . . . .
The boiler should be inspected and started annually, at
the beginning of the heating season, only by a qualified
service technician. In addition, the maintenance and
care of the boiler designated on page 6 and explained
on the following pages must be performed to assure
maximum boiler efficiency and reliability. Failure to
service and maintain the boiler and system could result
in equipment failure, causing possible severe personal
injury, death or substantial property damage.
Boiler must be serviced & maintained
The following information provides
detailed instructions for completing
the maintenance items listed in
the maintenance schedule, page 6.
In addition to this maintenance,
the boiler must be serviced and
started up at the beginning of each
heating season by a qualified service
technician.
9
Part Number 550-142-301/0420
User’s Information Manual
❏ Check daily . . . . . . . . . . . . . . . . .
Air openings
1. Verifythatcombustionandventilationairopenings
to the boiler room and/or building are open and
unobstructed.
Pressure/temperature gauge
or pressure gauge (steam)
1. Waterboilers— Makesurethepressurereading
on the boiler pressure/temperature gauge does
not exceed 24 psig. Higher pressure may indicate a
problem with the expansion tank or gauge.
2. Steamboilers—Makesurethepressurereadingon
theboilerpressuregaugedoesnotexceed15psig.
Higher pressure indicates a problem with the gauge
or limit control.
3. Contact a qualified service technician if problem
persists.
Venting system
Failure to inspect the vent system as noted above and
have them repaired by a qualified service technician can
result in vent system failure, causing severe personal
injury or death.
Boiler piping
Have leaks fixed at once by a qualified service technician.
Continual fresh makeup water will reduce boiler life.
Minerals can build up in sections, reducing heat transfer,
overheating cast iron, and causing section failure.
1. Visually inspect for leaks around piping, circulators,
relief valve and other fittings. Immediately call a
qualified service technician to repair any leaks.
1. Visuallyinspectallpartsortheue gas venting
system for any signs of blockage, leakage or joints
or deterioration of the piping.
2.
CGa and EG boilers:
a. With boiler firing, hold a candle or match below
loweredgeofdrafthood“skirt.”Ifamedoes
not blow out, but burns undisturbed, the vent
system is working properly.
Donotusepetroleum-based cleaning or sealing
compounds
inboilersystem.Severedamagetoboiler
and system components can occur, resulting in possible
severe personal injury, death or substantial property
damage.
❏ Check monthly . . . . . . . . . . . . . . . .
If flame blows out or flickers severely, the vent
system must be checked for obstructions or
other causes of improper venting.
b. Verify the vent damper (CGa and EG boilers)
opens before burners ignite.
3. Notify your qualified service technician at once if
you find any problem.
Boiler relief valve . . . . . . . . .
1. Inspect the boiler relief valve (see Figure 3) and the
relief valve discharge pipe for signs of weeping or
leakage.
2. If the relief valve often weeps:
•
water boilers — the expansion tank may not
be working properly.
•
steam boilers — limit control may be set too
high or there may be system problems.
• Immediatelycontactyourqualified service
technician to inspect the boiler and system.
Figure 3 Relief valve
User maintenance procedures (continued)
10
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Automatic air vents (if used)
1. SeeFigure 4.
2. Remove the cap from any automatic
air vent in the system and check
operation by depressing valve B
slightly with the tip of a screwdriver.
3. If the air vent valve appears to be
working freely and not leaking,
replace cap A, twisting all the way
on.
4. Loosen cap A one turn to allow vent
to operate.
5. Have vent replaced if it does not
operate correctly.
Pilot burner flame
Proper pilot flame (see Figure 5):
1. Blueame.
2. Inner cone engulfing thermocouple or thermopile (standing
pilot) or pilot flame sensor (spark-ignited pilot).
3. Thermocouple or thermopile, or pilot flame sensor glowing
cherry red.
Improper pilot flame:
1. Overred— Large ame lifting or blowingpastpilotame
sensor.
2. Underred—Smallame.Innerconenotengulngpilotame
sensor.
3. Lackofprimaryair—Yellowametip.
4. Incorrectly heated pilot flame sensor.
Main burner flame
Proper main burner flame (see Figure 6):
1. Yellow-orangestreaksmayappear(causedbydust).
Improper main burner flame:
1. Overred—Largeames.
2. Underred—Smallames.
3. Lackof primary air —Yellowtippingonames
(sooting will occur).
Figure 5 Pilot burner and flame, typical
Figure 6 Main burner flame, typical
❏ Check monthly . . . . . . . . . . . . . . . .
Check condensate drain
system (if used)
1. Inspectcondensatedrainttingsandtubing.Verify
that condensate can flow freely to drain.
Figure 4
Automatic air vent
User maintenance procedures (continued)
11
Part Number 550-142-301/0420
User’s Information Manual
Figure 7 Float type low water cutoff
Figure 8 Probe type low water cutoff
Probe type— See Figure 8
1. Cleanprobetypelowwatercutoffforproperoperation.
a. Turn off power to boiler and wait 5 minutes.
b. Drainwatertobottomofgaugeglass.
c. Turn on power.
d. Setthermostattocallforheat.Redneonlamponlower
water cutoff should light.
e. Wait 5 minutes. Boiler should not fire.
f. Refill boiler to correct water line. Red lamp should go off.
g. Wait 5 minutes. Boiler should fire.
h. Return thermostat to normal setting.
Test low water cutoff – The system is equipped with a low water cutoff. Test the low water cutoff periodically
during the heating season.
Float type — See Figure 7
1. Cleanoattypelowwatercutofftoclearoatchamberof
sediment.
a. Openblowdownvalveatbottomcontrol.
b. Drainwaterintoabucket.
. Boiler pressure and temperature must be low to
avoid the potential of severe burns from steam
or hot water.
2. Check float type low water cutoff for proper operation.
a. Turn operating control to call for heat.
b. Before water gets hot, drain to bottom of gauge glass.
Boiler should shut off after water level lowers a few inches.
c. Refill boiler to correct waterline. Boiler should come back
on.
❏ Service periodically . . . . . . . . . . . .
User maintenance procedures (continued)
Figure 9 Integtrated type low water cutoff
Integrated type— See Figure 9
1. TestLWCOusingcontrolLWCOTESTbutton.
a. Duringburnerre,pressLWCOTESTbutton.
b. Burner should shut off.
2. Clean periodically (when warning occur).
a. Turn off power to boiler wait 5 minutes.
b. Drainboilertoempty.
c. Remove sensor, wipe clean.
d. Re-installsensortospecied18ft/lbstorque.
e. Refill boiler to pressure, purge air.
f. Turn on boiler power.
g. Ensure proper operation resumes.
12
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Operate boiler relief valve
To avoid water damage or scalding due to
valve operation, a metal discharge line must be
connected to relief valve outlet and run to a safe
place of disposal. This discharge line must be
installed by a qualified heating installer or service
technician in accordance with the instructions
in the Boiler Manual.
The discharge line must be terminated so as to
eliminate possibility of severe burns should the
valve discharge.
1. Beforeproceeding,verifythatthereliefvalveoutlethasbeen
piped to a safe place of discharge, avoiding any possibility of
scalding from hot water.
2. Read the boiler pressure/temperature gauge to make sure the
system is pressurized.
3. Lift the relief valve top lever slightly, allowing water to relieve
through the valve and discharge piping.
4. If water flows freely, release the lever and allow the valve to seat.
Watch the end of the relief valve discharge pipe to ensure that
the valve does not weep after the line has had time to drain. If
the valve weeps, lift the seat again to attempt to clean the valve
seat. If the valve continues to weep afterwards, contact your
qualified service technician to inspect the valve and system.
5. If water does not flow from the valve when you lift the lever
completely, the valve or discharge line may be blocked.
Immediately shutdown the boiler, following the instructions
ontheinsidejackettopOperatingInstructions.Callyour
qualified service technician to inspect the boiler and system.
❏ Service every 6
months . . . . . . . .
Figure 10 Gauge glass
❏ Service periodically
continued . . . . . . .
Clean gauge glass
Normalwaterlineonasteamboilerishalfwayupgaugeglass.See
Figure10.Cleanwhenneeded.
1. Closelowergaugecock.
2. Openpetcock.
3. Openlowergaugecockandallowasmallamountofwaterto
flush out through open pet cock.
4. Close pet cock.
5. Openlowergaugecock.
6. If gauge glass breaks, close both gauge cocks and call a quali-
fied service technician to replace gauge glass. Do not replace
with thin glass tubing.
Boiler pressure must be low to eliminate po-
tential of severe burns.
Oil inducer motor (CGi boilers)
1. Use only SAE 20 motor oil. DO NOT use household universal
oils.
UseonlySAE20 motor oiltolubricatethe
inducermotor.Donotusecommonuniversal
household oils.
2. Place a few drops of oil in each of the two oiler cups on the
inducer motor.
User maintenance procedures (continued)
13
Part Number 550-142-301/0420
User’s Information Manual
Operating instructions
Use Table 2belowtolocatethecorrectOperatinginstructionforthegasvalvemodelinstalledonyourboiler.
Table 2
Operating
instruction
guide
Spark-ignited pilot Models Page
Honeywell VR8204/VR8304
CGa-25 thru CGa-8
EG-30 thru EG-75
PEG-30 thru PEG-55
13
CGi-3 thru CGi-6 17
White-Rodgers 36E
CGa-25 thru CGa-6
EG-30 thru EG-50
PEG-30 thru PEG-50
14
CGi-3 thru CGi-6 17
White-Rodgers 36C
CGa-7 & CGa-8
EG-55 thru EG-75
PEG-55
15
CGi-3 thru CGi-6 17
Robertshaw 7200
CGa-25 thru CGa-6
EG-30 thru EG-50
PEG-30 thru PEG-50
16
–– LGB 18
Follow boiler shutdown procedure
❏ End-of-season shutdown . . . . . . . .
2. Do not drain systemunlessexposuretofreezing
temperatures will occur.
3. Donotdrainthesystemifitis filled withan
antifreeze solution.
4. Donotshutdownboilersusedfordomesticwater
heating. They must operate year-round.
1. Follow“TO TURN OFF GAS TO APPLIANCE”onthe
Operating instructions
on the inside of the jacket
panel.Youwillalsondtheseinstructionsonpages
13through19ofthismanual.
Use the Operating instruction for the gas valve
model installed on the boiler.
Propane boilers only—Yourpropanesuppliermixesanodorantwiththepropanetomakeitspresencedetect-
able. In some instances, the odorant can fade and the gas may no longer have an odor.
• Propanegascanaccumulateatoorlevel.Smellneartheoorforthegasodorantoranyunusualodor.
If you suspect a leak, do not attempt to light the pilot.
• Usecautionwhenattemptingtolightthepropanepilot.Thisshouldbedonebyaqualiedservice
technician, particularly if pilot outages are common.
• Periodicallychecktheodorantlevelofyourgas.
• Inspectboilerandsystematleastyearlytomakesureallgaspipingisleak-tight.
• Consultyourpropanesupplierregardinginstallationofagasleakdetector.Therearesomeproductson
themarketintendedforthispurpose.Yoursuppliermaybeabletosuggestanappropriatedevice.
Propane gas odorant
User maintenance procedures (continued)
14
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Operating instructions
• Spark-ignited pilot
• Gas valve
— Honeywell VR8204/VR8304
CGa, EG-30 to EG-75,
PEG-30 to PEG-55,
15
Part Number 550-142-301/0420
User’s Information Manual
Operating instructions
• Spark-ignited pilot
• Gas valve — White-Rodgers 36E
CGa-25 to CGa-6,
EG-30 to EG-50,
PEG-30 to PEG-50
16
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Operating instructions
• Spark-ignited pilot
• Gas valve — White-Rodgers 36C
CGa-7, CGa-8,
EG-55 to EG-75,
PEG-55,
17
Part Number 550-142-301/0420
User’s Information Manual
Operating instructions
• Spark-ignited pilot
• Gas valve — Robertshaw 7200
CGa-25 to CGa-6,
EG-30 to EG-50,
PEG-30 to PEG-50
18
Part Number 550-142-301/0420
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Operating instructions
• Spark-ignited pilot
CGi
• Gas valve — Honeywell VR8204/VR8304, White-Rodgers 36C and 36E
19
Part Number 550-142-301/0420
User’s Information Manual
Operating instructions
• Spark-ignited pilot
LGB
20
Part No. 550-142-301/0420
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers
Symptom Common Causes Possible Corrections
Rapid cycling —
boiler turns on and
off frequently
Thermostat installed where drafts
or heat affect reading
Locate thermostat on inner wall away from heat sources or cool
drafts.
Heat anticipator in thermostat
adjusted incorrectly
Adjust thermostat per manufacturer’s instructions.
Incorrect limit setting Set limit according to system needs. Maximum setting is 220°F.
Increase limit setting to decrease cycling.
Insufcient water ow through
boiler
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Frequent release of
water through relief
valve
Expansion tank sized too small Call qualied service technician to check expansion tank
operation and size.
Flooded expansion tank Call qualied service technician to check expansion tank
operation.
Inoperative limit control Call qualied service technician to replace limit control.
Need to frequently
add makeup water
Leaks in boiler or piping Have qualied service technician repair leaks at once to avoid
constant use of makeup water. Makeup water can cause
mineral deposits which, in turn, can cause boiler section failure.
Do not use petroleum-base stop-leak compounds.
Black water
condition
Oxygen corrosion due to leaks in
boiler and piping
Have qualied service technician repair at once. Keep pH of
water between 7.0 to 8.5.
Popping or
percolating noise
heard in boiler
Mineral deposits in sections due
to constant use of makeup water
Call qualied service technician to de-lime boiler, if necessary.
In some cases, deposits will be too heavy to remove with de-
liming procedures.
Have qualied service technician repair leaks to eliminate need
for constant makeup water.
Incorrect pH of boiler water Call qualied service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
Insufcient water ow through
boiler
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Metal akes found in
vent outlet or vent —
ueway corrosion
Contaminated combustion air
supply — See page 3 in this
manual.
Remove any contaminating products. See page 3 in this
manual.
Provide outside air for combustion.
Condensation of combustion
gases in boiler sections
Have qualied service technician inspect system piping and con-
trols to verify proper regulation of return water temperature.
Some radiators or
baseboard units do
not heat or are noisy
Air in system Bleed air from system through air vents in radiators or
baseboard units.
Low system pressure Fill to correct pressure.
Check for leaks in boiler or piping. Have qualied service
technician repair at once.
High limit set too low Adjust high limit to higher setting.
Common problems and solutions
/